Lamp comprising multiple component designs and constructions

ABSTRACT

The present invention provides a bulb ( 100, 110, 120, 130, 140, 140 ′) an excitation chamber ( 200, 210, 220, 230, 230 ′) a ferrite core ( 300, 310, 310 ′), a spool ( 400, 410 ); an assembly or subassembly of such components, and a lamp ( 100, 1100, 1200, 1300, 1400, 1500, 1600, 1600′, 1600″, 1700, 1800 ) for producing electromagnetic radiation, such as in the light spectrum, UV or IR.

FIELD OF THE INVENTION

This invention relates to electrodeless radio frequency (RE) poweredexternal closed core electromagnetic (inductively coupled) fieldexcitation of a low pressure gas discharge light source or lamp andbulbs relating to same.

More specifically this invention relates to external electromagneticclosed core induction lamps that usually operate at the low RF frequencyof 250 Hz to 300 kHz and bulbs relating to same. However, this inventioncan also operate at low frequencies of 30 to 300 kHz, medium frequenciesof 300 kHz to 3000 kHz or higher frequency. Such lamps can produceelectromagnetic radiation in the ultra-violet, visible light, andinfra-red bands

BACKGROUND OF THE INVENTION

An electrodeless gas discharge (plasma) lamp can be driven by threedesign methods:

a) an electric field created by electrodes mounted outside the bulb orarc tube;

b) an electric field created by a medium RF frequency electromagneticfield usually in combination with a resonant cavity; or

c) an electric field created by a low to medium or higher RF frequencyelectromagnetic field without the use of a resonant cavity. This lamp isoften called an induction-coupled electrodeless lamp or “Inductionlamp”.

Induction lamps are split into two categories:

1) category 1 being lamps that use an external closed electromagneticcore usually in the shape of a torus: and

2) category 2 being lamps that use an open electromagnetic core usuallyin the shape of a rod.

Open core induction lamps of category 2 operate at frequencies of 1 MHzand above for efficient operation and are not the subject of theinvention and embodiments described herein.

Electrodeless closed external electromagnetic core induction lamps havebeen pioneered by many researchers as disclosed in U.S. Pat. No.3,500,118 issued Mar. 10, 1970 to Anderson, and the operationalprinciples outlined in Illuminating Engineering April 1969 pages 236-244as follows:

“An electrodeless inductively coupled lamp includes a low pressuremercury/buffer gas in a discharge tube which forms a continuous closedelectrical path. The path of the discharge tube goes through the centreof one or more toroidal ferrite cores such that the discharge tubebecomes the secondary of a transformer. Power is coupled to thedischarge by applying a sinusoidal voltage to a number of turns of wirewound around the toroidal core that encircles the discharge tube. Thecurrent through the primary winding creates a time varying magnetic fluxwhich induces along the discharge tube a voltage that maintains thedischarge. The inner surface of the discharge tube is coated with aphosphor which emits visible light when irradiated by photons emitted bythe excited mercury gas atoms.”

In an induction lamp a low to medium RF frequency magnetic field istypically used to create the electric field in the lamp eliminating theneed for electrodes. This electric field then powers the gas dischargeplasma.

There are presently few electrodeless closed core induction lamps on themarket due to the following reasons, listed in the next paragraph. Thereasons why electrodeless external electromagnetic closed core inductionlamp technology has not achieved market success, is that the currenttechnology does not appeal to users as a desirable light source to meettheir needs.

Some of the limitations of existing electrodeless lamps include:

-   -   they are physically too large, making them cumbersome;    -   they lack versatility in regard to their respective light        output;    -   they are Industrial in appearance and unappealing for commercial        and residential use;    -   they are awkward and it is expensive to utilise the light        generated due to their large bulb geometry;    -   they are relatively inefficient compared to competitive        commercially available lamps; and    -   they are expensive to manufacture and use due to their        relatively large and unwieldy bulb geometry.

Any reference herein to known prior art does not, unless the contraryindication appears, constitute an admission that such prior art iscommonly known by those skilled in the art to which the inventionrelates, at the priority date of this application.

SUMMARY OF THE INVENTION

This present invention and embodiments are primarily directed tocategory 1 external electromagnetic closed core induction lamps thatusually operate at the low to medium RF frequency.

Throughout the following description and claims, the word “lamp” whilenormally reserved for articles which produce visible light, will betaken to include such articles which produce any one of or two or moreof ultra-violet, visible light, and infra-red bands of electromagneticspectrum.

Throughout the following description and claims, the term “obround” isused to describe a general geometric shape. At the time of writing thisspecification and claims very few English dictionaries define this word.Notwithstanding, the word is used herein to describe a shape consistingof two semicircles connected by parallel lines tangent to theirendpoints, which generally looks as follows:

.

Lamps of the type to which this invention relates utilise a closedelectromagnetic core, coupled with a closed loop gas filled dischargetube that effectively becomes a single-turn secondary winding of atransformer enabling a plasma current to be generated. When the fieldwinding of the electromagnet is energised the excitation energy ofionized atoms and molecules returning to their ground state areconverted to electromagnetic radiation such as Ultra-Violet (UV),visible light, or Infra-Red.

It is an object of the present invention to present an improved designand a cost effective method of manufacture for an electrodeless closedcore induction lamp that ameliorates, at least in part, the abovedescribed limitations of existing electrodeless lamps.

The present invention provides a bulb for a lamp, the bulb including atleast one mounting interface having an outer periphery adapted to beconnected to an excitation chamber, the mounting interface including atleast two tubes extending away therefrom.

The two tubes extending from the mounting interface can be not connectedalong their length.

The two tubes extending from the mounting interface can be connectedintermittently or continuously along their length.

There can be one mounting interface and the two tubes, at an endopposite to the mounting interface that are in gas communication witheach other.

The tubes at an end opposite to the mounting interface can be joined byone of the following: a separate joining member to form at least a gascommunicating passage between the tubes; by being integrally formed withthe tubes to form at least a gas communicating passage between thetubes.

There can be two mounting interfaces and the tubes extend between thetwo mounting interfaces.

The two tubes can be of any shape including but not limited to, thefollowing cross sectional shapes: round; square; elliptical; ellipsoid;tear drop shape; triangular; triangular where apexes are oppositelyfacing each other; tear drop shape where the apexes are oppositelyfacing each other.

The bulb can be manufactured from any suitable material which istransparent or translucent such as any of the following: glass; silicaglass; quartz glass; a polymeric material; a composite material; a glassmaterial coated with graphene; a material coated with graphene whichenables a charged surface to be generated that will attenuate generatedradio frequencies emitted from a lamp made from the bulb.

The present invention also provides a method of manufacturing a tubularbulb for a lamp, the bulb being as described above, wherein the methodincludes the steps of: (a) forming a single first tube; (b) heating, ormaintaining the heat, of a central portion of the single tube to aworking temperature; and (c) applying pressure to the central portion soas to form two second tubes from the single first tube.

There can be included a further step, whether performed sequentially orsimultaneously, being of one of the following: maintaining at least oneend of said single first tube as being an original single first tubeshape; modifying at least one end of said single first tube to form adifferent shape or size to the original single first tube shape.

Step (c) can be performed by means of: a mould; any appropriate means.

Step (c) can create one of the following between the two second tubes: acontinuous web between them; an intermittent web between them; a spaceor void between them.

The preferred embodiment maintains one end as being the original singlefirst tube shape. However, it is recognised that it is possible to havea resultant shape or size differing from the single first tube.

At the end opposite to the one end, the two second tubes can beinitially left as open tubes.

At the end opposite to the one end, the two second tubes can beinitially left as open tubes but each has a joining flange formedtherein.

At the end opposite to the one end, the two second tubes can be joinedto each other so that gas communication between them can occur.

Two ends of the single first tube can be maintained in their originalsingle first tube shape.

The end or ends of the single first tube can include a mounting flangeto receive an excitation chamber.

The method can be performed sequentially to the single first tubeproduction process in such a manner as to utilise retained tube heatduring step (c). Alternatively, the method can be performed at a latertime to the single first tube production process.

The method can include the following steps: maintaining an extra singlefirst tube length portion for positioning, rotating or clamping in thesubsequent steps; trimming the ends of the single first tube to arriveat a finished bulb configuration.

The method can include the following subsequent steps: cleaning;applying an internal coating or coatings; inserting sub-assemblies;assembling sub-assemblies; welding, affixing, fusing or bonding on ofadditional sections or components; fusing additional sections orcomponents; applying an external coating or coatings; applyingexternally a graphene coating.

The method can be performed so that the two second tubes can be formedwith any cross sectional shape such as: round; square; elliptical;ellipsoid; tear drop shape; triangular; triangular where apexes areoppositely facing each other; tear drop shape where the apexes areoppositely facing each other.

The tube can be one of the following: glass; silica glass; quartz glass;a polymeric material; a composite material, a translucent material, atransparent material.

The present invention also provides an excitation chamber including aportion which has a generally U-shaped tubular portion the ends of whichhave at least one joining flange to engage at least one bulb of a matingshape.

The joining flange can be adapted to form a gas tight seal with the atleast one bulb.

The joining flange on each end of the U-shaped tubular portion can begenerally cylindrical.

The joining flange on each end can be a flared end and can be adapted toreceive a gas tight seal with respective tubular bulbs and allow forwelding, affixing, fusing or bonding thereto.

The at least one joining flange can be formed as a component separatefrom said tubular portion and is sealed or joined thereto with a gastight seal

The excitation chamber can be for use with a bulb as described above,and wherein the joining flange can be a single mounting flange to engagethe mounting interface of the tubular bulb, the single mounting flangeincluding two apertures therein which correspond to the two tubes of thetubular bulb.

The two apertures and the two tubes can be alignable, whereby theU-shaped tubular portion is generally alignable with a plane of the twotubes.

The excitation chamber can include one or more than one of the followingfeatures: an exhaust tube; an amalgam housing; an external coating; athermal barrier coating; a single piece moulding; a graphene coating onthe outside of the chamber; a graphene coating on the outside of thechamber which enables an electric charged surface to be generated thatwill attenuate generated radio frequencies emitted from a lamp made fromthe tubular bulb; an amalgam housing that can be thermally isolated fromthe lamp bulb.

The present invention also provides a lamp having an excitation chamberas described above.

The present invention further provides an electromagnet ferrite core,the core having a shape which includes a generally toroidal or obroundouter body with a centrally located diametrical portion, thereby formingone or more shaped apertures on each side of, or around, the centrallylocated diametrical portion.

The core, when an electromagnet is formed therefrom, can produce atoroidal or obround dipole magnetic field.

The core can be adapted to be separated through and re-joined through, aplane lateral to the direction of extension of the centrally locateddiametrical portion.

The core can be made of two or more pieces which have a general E shapeor rounded E shape and result in a shape representative of two general Eshape or rounded E shapes being assembled. It should be recognised thatthere are numerous variants to achieve a similar magnetic circuit forthis ferrite core.

The present invention also provides and excitation chamber and ferritecore subassembly, the core being as described above, and the excitationchamber being as described above.

A lamp having an excitation chamber and ferrite core subassembly asdescribed in the previous paragraph.

The present invention also provides a lamp having a ferrite core asdescribed above.

The present invention further provides an electromagnet being formedfrom a ferrite core as described above.

A coil or coils of wire can be formed continuously or at either one sideor at opposed locations on the centrally located diametrical portion.

The present invention also provides an electromagnet and excitationchamber subassembly, the electromagnet being described above, and theexcitation chamber being as described above.

The present invention further provides a lamp having an electromagnetand excitation chamber subassembly as described in the previousparagraph.

The present invention also provides a lamp having an electromagnet asdescribed above.

The present invention further provides a spool for an electromagneticfield coil for an electromagnet, the spool including a body having agenerally tubular construction which forms a central aperture and mayinclude at least one winding saddle being formed on the outside of thebody so as to wind a wire to form a coil, the spool and the coil beingable to be manipulated for assembly into a lamp.

The spool body can be of an elongate shape.

The spool body can be of a skeletal form.

A saddle can be formed at one end or at opposite ends of the spool body.

The spool body can be made from a polymeric material.

The spool can support a single coil at one end and is not compressibleor collapsible or deformable at the other end.

The spool can include at least one end which is deformable allowing thespool and the coil to be manipulated for threading through a spacebetween tubular components of a lamp.

Spool deforming can occur prior to, or during, insertion of a core forthe electromagnet.

The spool can be deformable by means of being collapsible in response toa compressive pressure or rotatable with respect to an axis lateral tothe direction of elongation of the body.

The spool can be deformable by means of collapsing around an axisparallel to a central longitudinal axis of the spool.

The spool can be deformable at opposed ends of the body.

The spool can have at least one end which is deformable in an elasticmanner.

The spool can have at least one end which is deformable in a plasticmanner, which will resume after deformation its original shape orsimilar, by insertion of a core of an electromagnet.

The present invention provides an electromagnet, spool and excitationchamber subassembly, wherein the electromagnet is as described above,and the excitation chamber is as described above, and the spool is asdescribed above.

A lamp having an electromagnet, spool and excitation chamber subassemblyas described in the previous paragraph.

The present invention also provides a lamp having an electromagnet witha spool as described above.

The present invention further provides an excitation chamber cover for alamp such as an electrodeless radio frequency powered external closedcore electromagnetic inductively coupled low pressure gas dischargeelectrodeless lamp or electromagnetic radiation source, the excitationchamber cover including a wall segment manufactured from a metal, thewall segment being coated on an inner surface with graphene.

The present invention also provides an excitation chamber cover for alamp such as an electrodeless radio frequency powered external closedcore electromagnetic inductively coupled low pressure gas dischargelight source, the excitation chamber cover including a wall segmentmanufactured from a metal, the wall segment including at least oneaperture there through.

The present invention further provides an excitation chamber cover beingconstructed of a non-metallic material and or composite which is, coatedinside and or outside with a graphene or similar conductive material sothat it can perform physical and other functions of a metallicexcitation chamber cover.

The excitation chamber cover and or the wall segment can be one of thefollowing: continuous; partially circumferential; circumferential; boxshape; square shape; rectangular shape.

An inner surface of the excitation chamber cover can be coated withgraphene.

The aperture or apertures can be present in an array, or in discretegroupings; or randomly across the periphery of the excitation chambercover or portion of the cover.

One end of the excitation chamber cover can include one or more flangesand openings therein.

The flange can support a polymeric disc, which can include a plug, lampholder cap and or terminal formations for connection or connecting anassembled lamp to a supply of electricity.

The excitation chamber cover can be one or both of a faraday cage and apassive heat sink.

The excitation chamber cover can perform the following functions:provides cooling of a ferrite core of an electromagnet; provides thermalstability to an amalgam housing; provides thermal stability to at leastone excitation chamber; provides physical protection to components andany integral electronics included within the excitation chamber cover;provides a means or mounting point for any integral electronic or otherlamp controller; provides a means or mounting point for a lamp holdercap; provides a bonding point for the bulb.

The present invention also provides a lamp having an excitation chambercover as described above. Such a lamp can also have one of thefollowing: an excitation chamber and ferrite core subassembly asdescribed above; an electromagnet and excitation chamber subassemblydescribed above; an electromagnet, spool and excitation chambersubassembly described above.

The present invention further provides an electrodeless radio frequencypowered external closed core electromagnetic inductively coupled lowpressure gas discharge electrodeless lamp or electromagnetic radiationsource, including a tubular bulb as described above.

The present invention also provides an electrodeless radio frequencypowered external closed core electromagnetic inductively coupled lowpressure gas discharge electrodeless lamp or electromagnetic radiationsource, including a tubular bulb as manufactured by the method describedabove.

The electrodeless lamp or electromagnetic radiation source can includean excitation chamber as described above.

The electrodeless lamp or electromagnetic radiation source can includean electromagnetic ferrite core as described above.

The electrodeless lamp or electromagnetic radiation source can includean electromagnet as described above.

The electrodeless lamp or electromagnetic radiation source can include aspool as described above.

The electrodeless lamp or electromagnetic radiation source can includean excitation chamber cover as described above.

The electrodeless lamp or electromagnetic radiation source can includeone or more of the following: electronic power controller; electricalpower controller; other controllers or power controllers; each of theforegoing being remote or integral with the source.

The electrodeless lamp or electromagnetic radiation source assembly canhave one of, or a combination of two or more of the following: theexcitation chamber is coated with graphene; the bulb is coated withgraphene; the excitation chamber cover is coated with graphene; theexcitation chamber is coated with graphene to form a faraday cage; thebulb is coated with graphene to form a faraday cage; the excitationchamber cover is coated with graphene to form a faraday cage.

The electrodeless lamp or electromagnetic radiation source can be suchthat the electromagnetic radiation generated is in one, or more thanone, of the following spectrums: ultraviolet; visible light; infra-red.

The present invention also provides a method of manufacturing anexcitation chamber for an electrodeless lamp or electromagneticradiation source, said chamber including a portion which has a generallyU-shaped tubular portion the ends of which have at least one joiningflange to engage at least one bulb of a mating shape, said methodincluding the steps of forming said generally U-shaped tubular portion,and forming a joining flange separate from said tubular portion, andassembling said joining flange and said tubular portion and joining andor sealing them together with a gas tight seal.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of a preferred embodiment will follow, by way ofexample only, with reference to the accompanying figures of thedrawings, in which:

FIG. 1 illustrates a perspective view of a tubular bulb which has abifurcated body and two mounting interface flanges;

FIG. 2 illustrates a side view of the tubular bulb of FIG. 1;

FIG. 3 illustrates an end view of the tubular bulb of FIG. 1;

FIG. 4 illustrates a perspective view of another tubular bulb which hasa bifurcated body and a single mounting interface flange;

FIG. 5 illustrates a side view of the tubular bulb of FIG. 4;

FIG. 6 illustrates an end view of the tubular bulb of FIG. 4;

FIG. 7 illustrates a perspective view of a further tubular bulb whichhas a bifurcated body with tubes of tear drop cross section and twomounting flanges;

FIG. 8 illustrates a side view of the tubular bulb of FIG. 7;

FIG. 9 illustrates an end view of the tubular bulb of FIG. 7;

FIG. 10 illustrates a perspective view of a tubular bulb which has abifurcated body with tubes of tear drop cross section and a singlemounting flange;

FIG. 11 illustrates a side view of the tubular bulb of FIG. 10;

FIG. 12 illustrates an end view of the tubular bulb of FIG. 10;

FIG. 13 illustrates a perspective view of a further tubular bulb whichhas a tubular body and is generally toroidal in shape;

FIG. 13A illustrates a side view of the tubular bulb of FIG. 13;

FIG. 14 illustrates a perspective view of a further tubular bulb whichhas a tubular body and is generally toroidal in shape;

FIG. 14A illustrates a side view of the tubular bulb of FIG. 14;

FIG. 15 illustrates a flow chart of an exemplary process for themanufacture of the tubular bulbs of FIGS. 1 to 14;

FIG. 16 illustrates a perspective view of an excitation chamber;

FIG. 17 illustrates side view of the chamber of FIG. 16;

FIG. 18 illustrates an end view of the chamber of FIG. 16;

FIG. 19 illustrates a perspective view of another excitation chamber;

FIG. 20 illustrates side view of the chamber of FIG. 19;

FIG. 21 illustrates an end view of the chamber of FIG. 19;

FIG. 22 illustrates a perspective view of a further excitation chamber;

FIG. 23 illustrates side view of the chamber of FIG. 22;

FIG. 24 illustrates an end view of the chamber of FIG. 22;

FIG. 25 illustrates a perspective view of another excitation chamber;

FIG. 26 illustrates side view of the chamber of FIG. 25;

FIG. 27 illustrates an end view of the chamber of FIG. 25;

FIG. 27A illustrates a perspective view of further excitation chamberwith added circular intermediate flange;

FIG. 27B illustrates an exploded perspective view of the components ofFIG. 27A;

FIG. 27C illustrates a rear view of the chamber of FIG. 27A;

FIG. 27D illustrates a side view of the chamber of FIG. 27A;

FIG. 27D2 illustrates a partial cross section of the flange of FIG. 27B;

FIG. 27E illustrates a perspective view of further excitation chamberwith added obround flange;

FIG. 27F illustrates an exploded perspective view of the components ofFIG. 27E;

FIG. 27G illustrates a rear view of the chamber of FIG. 27E;

FIG. 27H illustrates a side view of the chamber of FIG. 27G;

FIG. 27J illustrates cross section through the flange of FIG. 27F;

FIG. 27K illustrates a detail view of part of the cross section of FIG.27J;

FIG. 28 illustrates a flow chart of an exemplary process for themanufacture of the excitation chambers of FIGS. 16 to 27;

FIG. 29 illustrates a perspective view of a ferrite core of anelectromagnet;

FIG. 30 illustrates side view of the core of FIG. 29;

FIG. 31 illustrates an end view of the core of FIG. 29;

FIG. 32 illustrates a perspective view of another ferrite core of anelectromagnet;

FIG. 33 illustrates a side view of the core of FIG. 32;

FIG. 34 illustrates an end view of the core of FIG. 32;

FIG. 35 illustrates a perspective view of a winding spool for anelectromagnet;

FIG. 36 illustrates an end view of the spool of FIG. 35;

FIG. 37 illustrates a side view of the spool of FIG. 35;

FIG. 37A illustrates a perspective view of a hollow square orrectangular spool to form a coil for use with ferrite core of FIGS. 41to 43, and excitation chamber assembly of FIGS. 62A to 62C;

FIG. 38 illustrates a perspective view of another winding spool for anelectromagnet;

FIG. 39 illustrates an end view of the spool of FIG. 38;

FIG. 40 illustrates a side view of the spool of FIG. 38;

FIG. 41 illustrates a perspective view of another ferrite core of anelectromagnet;

FIG. 42 illustrates a side view of the core of FIG. 41;

FIG. 43 illustrates an end view of the core of FIG. 41;

FIG. 44 illustrates a perspective view of a wound coil produced on awinding spool for an electromagnet such as that of FIGS. 37 to 40;

FIG. 45 illustrates an end view of the coil of FIG. 44;

FIG. 46 illustrates a side view of the coil of FIG. 44;

FIG. 47 illustrates a perspective view of a wound coil produced on awinding spool for an electromagnet such as that of FIGS. 41 to 43;

FIG. 48 illustrates an end view of the coil of FIG. 47;

FIG. 49 illustrates a side view of the coil of FIG. 47;

FIG. 50 illustrates a part section perspective view of a sub-assembly ofa ferrite core half, spool and coil assembly with excitation chamberremoved for illustration purposes;

FIG. 51 illustrates a part section perspective view of the sub-assemblyof FIG. 50 of a ferrite core half, spool and coil assembly withexcitation chamber present and other half of ferrite core removed forillustration purposes;

FIG. 52 illustrates a side view of the sub-assembly of FIG. 51, withexcitation chamber present and other half of ferrite core removed;

FIG. 53 illustrates an end view of the sub-assembly of FIG. 51;

FIG. 54 illustrates a part section perspective view of a furthersub-assembly of a ferrite core half, spool and coil assembly withexcitation chamber present and other half of ferrite core removed forillustration purposes;

FIG. 55 illustrates a side view of the sub-assembly of FIG. 54;

FIG. 56 illustrates an end view of the sub-assembly of FIG. 54;

FIG. 57 illustrates a part section perspective view of anothersub-assembly of a ferrite core half, spool and coil assembly withexcitation chamber present and other half of ferrite core removed;

FIG. 58 illustrates a side view of the sub-assembly of FIG. 57;

FIG. 59 illustrates an end view of the sub-assembly of FIG. 57;

FIG. 60 illustrates a part section perspective view of anothersub-assembly of a ferrite core half, spool and coil assembly with twoexcitation chambers present and the other half of ferrite core removedfor illustration purposes;

FIG. 61 illustrates a side view of the sub-assembly of FIG. 60;

FIG. 62 illustrates an end view of the sub-assembly of FIG. 60;

FIG. 62A illustrates a part section perspective view of anothersub-assembly of a ferrite core half (as illustrated in FIGS. 27E to27H), spool and coil assembly and the other half of ferrite core removedfor illustration purposes;

FIG. 62B illustrates a rear view of the sub-assembly of FIG. 62A;

FIG. 62 illustrates an side view of the sub-assembly of FIG. 62A;

FIG. 63 illustrates a perspective view of an excitation chamber cover;

FIG. 64 illustrates a side view of the excitation chamber cover of FIG.63;

FIG. 65 illustrates an end view of the excitation chamber cover of FIG.63;

FIG. 66 illustrates a perspective view of another excitation chambercover;

FIG. 67 illustrates a side view of the excitation chamber cover of FIG.66;

FIG. 68 illustrates an end view of the excitation chamber cover of FIG.66;

FIG. 69 illustrates a perspective view of a lamp assembly embodying thecomponents of previous figures having a tubular bulb body of FIGS. 1 to3, and an excitation chamber/spool/core/coil/cover sub-assembly at bothends with one cover, and one ferrite core half, removed for illustrationpurposes;

FIG. 70 illustrates a plan view of the lamp assembly of FIG. 69 withboth excitation chamber covers present;

FIG. 71 illustrates a side view of the lamp assembly of FIG. 69 withboth excitation chamber covers, and one ferrite core half, removed forillustration purposes;

FIG. 72 illustrates a detail perspective view of the end of lampassembly of FIG. 69 with excitation chamber cover, and one ferrite corehalf, removed for illustration purposes;

FIG. 73 illustrates an end view of the lamp assembly of FIG. 69;

FIG. 74 illustrates a perspective view of a lamp assembly embodying thecomponents of previous figures having a tubular bulb body of FIGS. 4 to6, and an excitation chamber/spool/core/coil/excitation chamber coversub-assembly at one end with one excitation chamber cover, and oneferrite core half, removed for illustration purposes;

FIG. 75 illustrates a plan view of the lamp assembly of FIG. 74 withexcitation chamber cover present;

FIG. 76 illustrates a side view of the lamp assembly of FIG. 74 withexcitation chamber cover, and one ferrite core half, removed forillustration purposes;

FIG. 77 illustrates a bulb end view of the lamp assembly of FIG. 74

FIG. 78 illustrates a detail perspective view of the excitation chamberend of the lamp assembly of FIG. 74 with excitation chamber cover, andone ferrite core half, removed for illustration purposes;

FIG. 79 illustrates a excitation chamber cover end view of the lampassembly of FIG. 74 with excitation chamber cover absent;

FIG. 80 illustrates a perspective view of a lamp assembly embodying thecomponents of previous figures having a tubular bulb body of FIGS. 10 to12, and an excitation chamber/spool/core/coil/excitation chamber coversub-assembly at one end with excitation chamber cover, and one ferritecore half removed for illustration purposes;

FIG. 81 illustrates a plan view of the lamp assembly of FIG. 80 withexcitation chamber cover present;

FIG. 82 illustrates a side view of the lamp assembly of FIG. 80 withexcitation chamber cover, and one ferrite core half, removed forillustration purposes;

FIG. 83 illustrates a bulb end view of the lamp assembly of FIG. 80

FIG. 84 illustrates a detail perspective view of the excitation chambercover end of lamp assembly of FIG. 80 with excitation chamber cover, andone ferrite core half, removed for illustration purposes;

FIG. 85 illustrates a perspective view of a further lamp assemblyembodying the components of previous figures having a tubular bulb asillustrated in FIGS. 7 to 9, and an excitationchamber/spool/core/coil/excitation chamber cover sub-assembly at bothends with one excitation chamber cover, and one ferrite core half,removed for illustration purposes;

FIG. 86 illustrates a plan view of the lamp assembly of FIG. 85 withboth excitation chamber covers present;

FIG. 87 illustrates a side view of the lamp assembly of FIG. 85 withboth excitation chamber covers, and one ferrite core half, removed forillustration purposes;

FIG. 88 illustrates a detail perspective view of a excitation chambercover end of lamp assembly of FIG. 85 with excitation chamber cover, andone ferrite core half, removed for illustration purposes;

FIG. 89 illustrates a perspective view of another lamp assemblyembodying the components of previous figures having two single tubularbulb bodies, and an excitation chamber as illustrated in FIGS. 22/22A to24 in an excitation chamber/spool/core/coil/excitation chamber coverssub-assembly at both ends with one excitation chamber cover, and oneferrite core half, removed for illustration purposes;

FIG. 90 illustrates a plan view of the lamp assembly of FIG. 89 withboth excitation chamber covers present;

FIG. 91 illustrates a side view of the lamp assembly of FIG. 89 withboth excitation chamber covers, and one ferrite core half, removed forillustration purposes;

FIG. 92 illustrates a detail perspective view of excitation chamber endof lamp assembly of FIG. 89 with excitation chamber cover, and oneferrite core half, removed for illustration purposes;

FIG. 93 illustrates the excitation chamber cover end view of the lampassembly of FIG. 89;

FIG. 94 illustrates a perspective view of a further lamp assemblyembodying the components of previous figures having a tubular bulb, andan excitation chamber as illustrated in FIGS. 22 to 24 in an excitationchamber/spool/core/coil/excitation chamber cover sub-assembly at one endwith excitation chamber cover, and ferrite core half, removed forillustration purposes;

FIG. 95 illustrates a plan view of the lamp assembly of FIG. 94 withexcitation chamber cover present and showing an Edison screw typefitting lamp holder;

FIG. 96 illustrates a side view of the lamp assembly of FIG. 94 withexcitation chamber cover, and ferrite core half, removed forillustration purposes;

FIG. 97 illustrates a detail perspective view of the excitation chambercover end of lamp assembly of FIG. 94 which has an excitation chambercover, and a ferrite core half, removed for illustration purposes;

FIG. 98 illustrates a perspective view of a further lamp assemblyembodying components of previous figures having a tubular bulb asillustrated in FIGS. 13 and 13A, and excitation chamber as illustratedin FIGS. 25/25A to 27 in an excitationchamber/spool/core/coil/excitation chamber cover sub-assembly;

FIG. 99 illustrates a plan view of the lamp assembly of FIG. 98;

FIG. 100 illustrates a side view of the lamp assembly of FIG. 98;

FIG. 101 illustrates a detail perspective view of the cap of lampassembly of FIG. 98;

FIG. 101A illustrates an exploded perspective view of a lampsub-assembly having a single generally toroidal or round tubular bulband excitation chamber as shown in FIGS. 27E to 27K illustrating theexcitation chamber and intermediate flange components;

FIG. 101B illustrates an exploded perspective view of a lamp assemblyhaving a single generally toroidal or round tubular bulb and excitationchamber as shown in FIGS. 27E to 27K illustrating the excitation chamberand intermediate flange components and excitation chamber cover and aninboard lamp holder;

FIG. 101C illustrates a perspective view of an assembled lamp having asingle generally square tubular bulb and excitation chamber as shown inFIGS. 27E to 27K with an intermediate flange like in FIG. 101A and FIG.101B, with excitation chamber cover and an inboard lamp holder alsoassembled.

FIG. 102 illustrates a flow chart of an exemplary process for themanufacture of the lamps of FIGS. 77 to 101;

FIG. 103 illustrates a close up view of the optional access hole 104.1for cabling to enable power distribution to the second end of a doubleended lamp;

FIG. 104 illustrates a perspective view of another lamp assemblyembodying the components of previous figures having two single tubularbulb bodies, and excitation chambers as illustrated in FIGS. 19 to 21 inan excitation chamber/spool/core/coil/excitation chamber coverssub-assembly at both ends with one excitation chamber cover, and oneferrite core half, removed for illustration purposes;

FIG. 105 illustrates a plan view of the lamp assembly of FIG. 104 withboth excitation chamber covers present;

FIG. 106 illustrates a side view of the lamp assembly of FIG. 104 withboth excitation chamber covers, and one ferrite core half, removed forillustration purposes;

FIG. 107 illustrates a detail perspective view of an excitation chambercover end of lamp assembly of FIG. 104 with excitation chamber cover,and one ferrite core half, removed for illustration purposes;

FIG. 108 illustrates a excitation chamber cover end view of the lampassembly of FIG. 104;

FIG. 109 illustrates a perspective view of another lamp assemblyembodying the components of previous figures having a U-shaped tubularbulb body (or two straight tubes with a 180 degree joining piece), andan excitation chamber as illustrated in FIGS. 19 to 21 in an excitationchamber/spool/core/coil/cover sub-assembly one end with its excitationchamber cover, and one ferrite core half, removed for illustrationpurposes;

FIG. 110 illustrates a plan view of the lamp assembly of FIG. 109 withthe excitation chamber cover present and showing a bayonet type fittinglamp holder;

FIG. 111 illustrates a side view of the lamp assembly of FIG. 109 withthe one excitation chamber cover, and one ferrite core half, removed forillustration purposes;

FIG. 112 illustrates a detail perspective view of the excitation chambercover end of lamp assembly of FIG. 109 with excitation chamber cover,and one ferrite core half, removed for illustration purposes;

FIG. 113 illustrates a excitation chamber cover end view of the lampassembly of FIG. 104; and

FIG. 114 illustrates a perspective view of another lamp assemblyembodying the components of previous figures having two straight tubes,and an excitation chamber/spool/core/coil/cover sub-assembly at each endas illustrated in FIGS. 27A to 27D, with one excitationchamber/spool/core/coil/cover sub-assembly being shown in an explodedview for illustration purposes.

DETAILED DESCRIPTION OF THE EMBODIMENT OR EMBODIMENTS

Bulb Features and Construction

As is depicted in FIGS. 1 to 14, there are illustrated several bulbconstructions, which have different features which will be described inmore detail below.

Illustrated in FIGS. 1 to 3 is a tubular bulb 100 for a lamp (such aslamp 1000 of FIG. 69), the tubular bulb 100 includes at least onemounting interface 101, in this case there are two mounting interfaces101, being one at each end. The mounting interfaces 101 having an innerperiphery 101.1 adapted to be connected to an excitation chamber (seebelow), with the mounting interface 101 including at least two tubes 102extending away therefrom. The mounting interface 101 has its innerperiphery 101.1 being illustrated as, and is preferably, a circular orcircumferential rim. However, it will be understood that the mountinginterface 101 can have an inner periphery of any appropriate shape orconfiguration. The mounting interface 101 can be cavity or recessformation into which is received a mating periphery or formation on theexcitation chamber (see below). Alternatively, the mounting interface101 can be a periphery or formation, which is received into a cavity orrecess formation on the excitation chamber.

The inner periphery 101.1 transitions from its circular outer shape by atransition surface 101.2 into the start of two tubes 102. At thelocation of intersection of the two shapes from the transition surface101.2 to the tubes 102, is a further transition surface 102.1, whichbecause of its smooth blending of surfaces and tangential nature, andthe transparent nature of the tubular bulb 100, may not been seen in thefinal tubular bulb 100.

In the embodiment of FIGS. 1 to 3, the two tubes 102 are formed from asingle piece of cylindrical tubing, as will be described in more detaillater, whereby the sides of the original tubing are pushed or moulded orformed in a direction towards the central axis of the tube, so that theinner surfaces of the original tube meet and close at the central web103 in FIG. 3, which web 103 from FIG. 2 extends between the transitionsurface 101.2 on one end to the other transition surface 101.2 on theother end of the tubular bulb 100. The web 103 extends between themounting interfaces 101 in a continuous manner, but it will beunderstood that it could also do so in an intermittent manner or onlypartially along the whole length of the tubular bulb 100.

The two tubes 102 are illustrated in FIGS. 1 to 3 as being of agenerally cylindrical cross section, however, any appropriate crosssection can be utilised depending upon the light effect to be producedor the purpose to which the light will be utilised. Such shapes caninclude square, elliptical, ellipsoid, tear drop shape (which will bedescribed in more detail below), triangular; triangular where apexes areoppositely facing each other; tear drop shape where the apexes areoppositely facing each other, or a multitude of other shapes. While itis expected that for most applications that the two adjacent tubes 102are, or will be, of the same cross section, this does not need to be thecase, and different or combinations of cross sections could be utilisedand made.

The tubular bulb 100 can be manufactured from a material which istransparent or translucent, such as: glass; silica glass; quartz glass;a polymeric material; a composite material. If required or desired theoutside of the tubular bulb 100 can be coated with graphene. Thegraphene coating when charged, will enable a surface to be generatedthat will assist to attenuate generated radio frequencies emitted from alamp, such as lamp 1000 of FIG. 69, made from said tubular bulb 100.

Illustrated in FIGS. 4 to 6 is another embodiment of a tubular bulb 110,which is similar to that of tubular bulb 100 of FIGS. 1 to 3, and likeparts are like numbered. The tubular bulb 110 differs from that of bulb100, by there being only one mounting interface 101 at one end. Theother end has a generally “U-shaped” or 180 degree union or joiningpiece 102.5, generally made of the same material as the tubes 102, whichallows the passages through the respective tubes 102 to be in gascommunication with each other. This will allow ionised gases to movefreely from one tube 102 to the other when energised or not, as the casemay be.

The union or joining piece 102.5 can be made separately to the tubes 102and joined thereto in a subsequent production step, or if desired, thejoining piece or union 102.5 can be made integrally with the tubes 102,when they are being formed.

The tubular bulbs 100 and 110 as described above in relation to FIGS. 1to 6, have the web 103 extending along the line of the connection of thetubes 102. However, if required the forming process could completelyseparate the tubes 102, such that the web 103 will cease to exist, andthe tubes 102 will be near to each other, but separate.

Illustrated in FIGS. 7 to 9 is another embodiment of a tubular bulb 120,which is similar to the previously described bulbs 100 and 110, and likeparts have been like numbered. The tubular bulb 120 differs from thebulb 100 only in the cross section of the tubes 102. The tubes 102 areof tear-drop or piriform shape with an apex of one tube 102 meeting theapex of the other tube 102 to form the web 103 (this can also bereferred to as a sextic form). The opposed tear drop or piriform shapehas the advantage that light radiating from the opposed surfaces oneither side of an apex on one tube 102, is in the main not blocked orinternally reflected by the opposed tube 102. The purpose of thisopposed piriform bulb geometry is to minimise internal reflections andself-shading within the ultimate lamp phosphor coated bulb and this willassist to achieve an optimal light generation from the light source. Theopposed piriform shape can be achieved by a sextic curve or similarshaped mould to achieve a double but opposed piriform shape asillustrated in FIGS. 7 to 9.

Illustrated in FIGS. 10 to 12, is an embodiment of tubular bulb 130,which is similar to the tubular bulb 110 of FIGS. 4 to 6 in that it hasa single mounting interface 101, but is similar to the tubular bulb 120of FIGS. 7 to 9 in that the two tubes 102 each have opposed tear-drop orpiriform shapes. Like parts have been like numbered. The “U-shaped”union or joining piece 102.5 also has a piriform shape revolved through180 degrees, to provide a fluid communicable passage between the tubes102.

Illustrated in FIGS. 13 and 13A is a tubular bulb 140, which has agenerally toroidal shape to form an open ring shaped tubular bulb 140.From the side view of FIG. 13A, it can be seen that the bulb 140 has twotubes 102 which are of a generally circular or cylindrical crosssection, in the same manner as that of FIGS. 1 to 6, and like parts havebeen like numbered. As with the other previously described bulbs 100,110, 120 and 130, the ultimate operational, aesthetic or performancerequirements of the bulb 140 will dictate what cross section isutilised.

The tubular bulb 140 has four mounting interfaces 101, which extendradially inwardly near the ends of the tubes 102. The ends of the tubes102 may each terminate in a hemispherical end 102.11. The mountinginterfaces 101, of which only the upper two are visible in FIG. 13, forthe attachment of two excitation chambers, as will be described in moredetail below. The mounting interfaces 101 are of a straight-cut variety,and are simply the terminating ends of a cylindrical section. As will bedescribed in more detail later, these interfaces 101 will be receivedinto cavity or recess interfaces on an excitation chamber.

Illustrated in FIGS. 14 and 14A is a single curved tubular bulb 140′,which is part toroid or part round, which has a generally toroidal shapeto form an open ring shaped tubular bulb 140′. From the side view ofFIG. 14A, it can be seen that the bulb 140′ has a single tube 102′ whichis of a generally circular or cylindrical cross section. As with theother previously described bulbs 100, 110, 120 and 130, 140, theultimate operational, aesthetic or performance requirements of the bulb140′ will dictate what cross section is utilised.

The tubular bulb 140′ has two mounting interfaces 101′, visible in FIG.14, for the attachment of the excitation chamber, as will be describedin more detail below. The mounting interfaces 101′ are of a straight-cutvariety having tapered ends 101.1 to be received into the intermediateflange cavity or recess interface of an excitation chamber FIGS. 27E to27H as will be described in more detail below.

Method of Making the Tubular Bulb

The above described tubular bulbs 100, 110, 120, 130 and 140, can bemade by an exemplary process as illustrated in schematic fashion theflow chart of FIG. 15. The process steps will now be described in moredetail.

A brief summary of this process is that the tubular bulbs, such as 100,110, 120, 130 and 140 from FIGS. 1 to 14, can be formed from one singlestraight original circular tube, preferably of glass, of a predetermineddiameter that when a central portion of this original tube is heated toits softened working state, it can be further moulded using conventionallamp glass making machinery to enable a bifurcated section of anyrequired cross sectional shape. This original tube bifurcation achievestwo further distinct tubes 102 as described above, yet they remain partof the original circular straight tube with at least one open end (twoare required for a double ended lamp or one for a single ended lamp) yetthe bifurcated tube 102 behaves as separate tubular cavitiessimultaneously as required for a double ended, single ended and circularlamp.

The method of manufacturing the tubular bulbs 100, 110, 120, 130, 140 asdescribed above, includes the steps of: (a) forming a single first tube(the later remainder of which forms rim or rims 101.1 and mountinginterface 101); (b) heating, or maintaining the heat, of a centralportion of the single tube to a working temperature; (c) applyingpressure the central portion so as to form two second tubes 102 from thesingle first tube.

An additional step can be performed sequentially or simultaneously withthe method, namely that of maintaining at least one end of the singlefirst tube as being an original single first tube shape; oralternatively modifying at least one end of the single first tube toresult in a different shape or size to the original single first tubeshape.

Step (c) is preferably performed by means of a mould or any appropriatemeans and it creates one of the following between the two second tubes102: a continuous web 103 between them; an intermittent web between them(not illustrated); a space or void between them (not illustrated).

The method of manufacture, when single ended tubular bulbs 110, 130 areto be made, will leave only one end maintained as being the originalsingle first tube shape. For single ended tubes or tubular bulbs 110,130, the manufacturing method will either preferably form a U-shaped or180 degree union 102.5 simultaneously in the mould described in thepreceding step; or will, at the end opposite to the one end, leave openthe two second tubes 102. If the second tubes 102 are left open, theycan later be joined to each other, by a U-shaped or 180 degree union orjoining piece 102.5, so that they are in gas communication with eachother. Such a later join can be made by any appropriate means such asbutt welding; joining flanges; fused joins etc.

At some point further in the production process the method will alsoinclude one or more of the following steps: maintaining an extra singlefirst tube length portion for positioning, rotating or clamping in thesubsequent steps; trimming the ends of the single first tube to arriveat a finished bulb configuration; cleaning; applying an internal coatingor coatings; inserting sub-assemblies; assembling sub-assemblies;welding, affixing, fusing or bonding of additional sections orcomponents; fusing additional sections or components; applying anexternal coating or coatings; applying externally a graphene coating.

The bifurcation forming stage can be introduced into the glass tubeproduction process, optimally in line in such a manner as to utiliseretained tube heat during the glass drawing process. Equally thebifurcation forming stage may be performed at a later time requiringhigher input energy to reheat the material to the required formingtemperature. Refer flowchart describing the potential manufacturing andassembly process for bifurcating the bulb body of a typical linear lamp.

The resultant bifurcated tube may not be the finished shape in that itmay contain an extra or remaining length of original single tube lengthportion that was retained for positioning, rotating or clamping in thesubsequent assembly and manufacturing process (either automated ormanual). This extra or remaining length of original single tube lengthportion would be trimmed within the manufacturing process to arrive atthe finished lamp tubular bulb configuration.

The benefits which can be achieved by these tubular bulb constructionsand manufacturing processes include: better or high speed production;energy efficient production as it uses residual heat from the glassdrawing line; it enables a wide range of bulb cross-section geometry dueto body moulding possibilities; it enables greater bulb rigidity aswebbing 103 and ribbing bosses can be introduced into the bulb shape; itenables potential for embedded power cabling within the bifurcated webfor transferring power from one end of the lamp to the other end, givingadded safety, physical and electrical protection to the user andcabling—this will be described in more detail below.

As illustrated in FIG. 15, the method of making the tubular bulbs 100,110, 120, 130 and 140, comprises steps as indicated above and below,which are included in the flow chart illustrated, to which someadditional commentary is provided as follows, wherein the number of thecomment, namely 1 to 10, is located at, and directed to, particularsteps in the flowchart of FIG. 15:

Comment 1: Glass raw materials are fed into the furnace in order toproduce the desired glass required e.g. soda ash, quartz or other, inaccordance with the manufacturer's specifications. Glass is thenintroduced into a mandrel, nozzle or some other apparatus where it istypically interfaced with air in order to draw a hollow original tube,typically in accordance with one of the more widely acceptedmanufacturing fundamentals.

Comment 2: The single original tube will travel either vertically undergravity or by some other means to a point where it has slightly cooledand will engage with either an air or some other form of conveyor (notillustrated). This conveyor will carry the single original tube adistance to the next station by which time it will have hardened and beof the desired final shape, straightness etc.

Comment 3: By the time the single original tube reaches the tube cut offstation it will have cooled significantly and will be at the optimumtemperature to allow it to be cut to approximate length. The originaltube may be cut by means of thermal shock, mechanical apparatus or someother means.

Comment 4: The single original tube having been cut into individuallengths will now enter either an inline or parallel series of heatingchambers (dependent on the manufacturing plant, throughput etc.). Eachheating station will heat the lengths of glass original tube to anoptimal forming temperature until they are passed into the cavitymould(s).

Comment 5: Upon entering the cavity mould station, the single originaltube will be partially pressurized with a gas, and a force applied tothe mould in order to create the bifurcated shape of bulb designated bythe respective design, as illustrated in FIGS. 1 to 14. Creation ofnonlinear tubular bulbs, such as that shown in FIG. 13 requires anadditional forming process to arrive at the desired geometry. Thisadditional forming can be performed at this stage or alternatively afterthe actions in Comment 9 below, or at some other time.

Comment 6: Dependent upon the manufacturing process utilised andresidual heat within the bifurcated bulb, the tube may be heated beforethe tube trim station or may be heated after the trim station. Eitherway, sufficient heat must be present to size the end of the bifurcatedlamp post trimming. Alternative to this separate station, themanufacturer may elect to trim the single original tube to the exactlength immediately after moulding and whilst still held captive by themould, or immediately afterwards. If performed in a separate station,fine positioning may be required prior to trimming.

Comment 7: The tubular bulb end(s), being the original diameter of thesingle original tube, are sized for later connection to a predeterminedexcitation chamber, as will be described in more detail below.

Comment 8: The now bifurcated tubular bulb will then be conveyed to thecleaning station in accordance with the manufacturer's processpreference. It is possible that the conveyor will transition the nowbifurcated tubular bulb from the horizontal to vertical plane where itwill ultimately be cleaned and rinsed to remove any debris or chemicalsresulting from the previous manufacturing steps. A chemical applicationis applied to the internal wall of the bifurcated tubular bulb in orderto seal same.

Comment 9: The cleaned and treated open bifurcated tubular bulbprogresses to the next station where a phosphor solution is applied (inthe case of a visible light lamp) to the entire internal surface of thetubes 102 and is subsequently drained to a prescribed thickness. Excesssolution is removed from the ends of the bifurcated tubular bulb whichwill later interface with the excitation chamber. Lamps designed forother applications such as Ultra violet and infra-red may or may notinclude a phosphor lining and hence may not have a solution applied asdescribed above.

Comment 10: The bifurcated and coated tubes are conveyed through an ovento remove any residual binder chemicals which had been included in thephosphor or other solution.

Excitation Chamber Features and Construction

Illustrated in FIGS. 16 to 18 is a first excitation chamber 200. Thechamber 200 has a mounting flange 201 which has a cylindrical outer rim201.1, and is of a diameter so as to closely mate with, and or engagewith, the mounting interfaces 101 of the tubular bulbs 100, 110, 120 and130, so that the respective passages of tubes 102 will be aligned withtwo excitation tubes 202 forming part of the excitation chamber 200.Between the two excitation tubes 202 and behind the mounting flange 201,is a space or gap 203 through which can be threaded a spool (see spool510 below) on which is located coil windings, so as to locate coilwindings adjacent to the sides of the excitation tubes 202, as will bedescribed in detail below. It will be noted in FIG. 16, that the facingsurfaces of the tubes 102 are generally straight, as is evident by theflat peripheries 202.1. The flat peripheries 202.1 produce a flat uppersurface and flat lower surface which bounds the space or gap 203 by theexcitation tubes 202, behind the flange 201.

Likewise with the tubular bulbs described above, the intersection of theoutlet of the excitation tubes 202 with the face 204 of the excitationchamber 200, as depicted by transition surface or radii 202.2 would notbe seen in the glass or transparent construction of the excitationchambers 200, because the transition surfaces 202.2 at their extremitiesare tangential to the internal shape of the tube portion 202 and thesurface 204.

The surface 204, as best seen from FIG. 17, has an angled outer surfaceon the flange 201, which approximates or matches the hollow transitionsurface 101.2 on the tubular bulbs 100, 110, 120 and 130. The meeting ofsurfaces 204 and 101.2, and the outer circumferential rim 201.1 with theinner circumferential surface of the rim 101.1, ensures that a gas tightseal can be made, whether by fusing, welding or otherwise adhering thetransition surfaces 202.2 to the transition surface 102.1.

The excitation chamber 200 as best seen from FIGS. 16 to 18 includes anevacuation tube 207 located at the rear of the excitation chamber 200between the upper end of the connection section 205 and the rear end ofthe upper tube 202, with the evacuation tube 207 extending rearwardly inthe general direction of extension of the tubes 202. Additionally, theexcitation chamber 200 also includes an amalgam housing 206 which isapproximately centrally located on the connection section 205, and atthe side thereof, and extending in a sidewards direction. The amalgamhousing can alternatively be sited at other locations and can extendrearwardly in a similar manner to the evacuation tube as describedabove. More will be described about these in the description below.

The excitation chamber 200, whilst having the above described featuresfor sealingly interacting with the mounting interfaces 101 of thepreviously described bulbs, will also allow the connection, by weldingor fusing etc. of an appropriately shaped end of a tube, which may bestraight or u-shaped, or some other appropriate shape.

Illustrated in FIGS. 19 to 21 is another excitation chamber 210, whichis similar to that of FIGS. 16 to 18, and like parts have been likenumbered. The excitation tubes 202 of excitation chamber 210 do notdiffer from that of chamber 200. The primary difference of thisexcitation chamber is that it permits use of circular tubes, whetherindividual, or part of a bifurcated bulb. While this excitation chamberaccepts a circular tube into opening 202.1, there is an internaltransition surface to the preferred excitation chamber geometrydescribed earlier in relation to FIGS. 16 to 18.

It should be noted that the excitation tubes 202 for an excitationchamber could be made of any cross sectional shape, anywhere in theexcitation chamber, including that area surrounded by the ferrite core.Such cross sectional shapes can include circular, triangular square,obround or rectangular. This list not exhaustive.

As described above, the excitation chamber 210, by virtue of mountingflange 201 is connectable to circular straight tubes or U-tubes toproduce a lamp as shown in FIG. 89 or FIG. 94. Further, like theexcitation chamber 200, the excitation chamber 210 can be provided witha surface 204 which allows engagement with respective mountinginterfaces 101 of the tubular bulbs 100,110,120, 130 described earlier.The excitation chamber 210 will thus be useful in constructing lampswhere bifurcated bulbs may not be available.

Illustrated in FIGS. 22 to 24 is an excitation chamber 220, which issimilar in construction to that of excitation chamber 210 of FIGS. 19 to21, and like parts have been like numbered. The excitation chamber 220differs from the excitation chamber 210 in that the joining ends of thetubes 202 each terminate in their own recess or cavity type joiningflange 201, which has a circumferential or circular rim 201.1 around it,so as to receive a straight cut end of a cylindrical tube. The joiningflange 201 can be formed on the tube ends 202 after the U-shapeconfiguration of tubes 202, 205 and 202 is formed or before on the endsof a straight length of tube and then bent into a U-shaped excitationchamber. By either method, a space or gap 203 will be formed as in thepreviously described excitation chambers, which will provide a gap intowhich a spool and coil windings can be assembled.

Illustrated in FIGS. 25 to 27 is another excitation chamber 230, whichis similar to that of excitation chamber 220 of FIGS. 22 to 24, and likeparts have been liked numbered. The difference is that the excitationchamber 230 has a horizontal offset portion 202.3 on the ends of each ofthe tubes 202, which leads to the recess/cavity type mounting flanges201. It will be understood that in some circumstances an offset, both inthe same vertical direction, or in opposite vertical directions, can beproduced due to the lamp requirements.

Illustrated in FIGS. 27A to 27D is an excitation chamber 220′, which issimilar in construction to that of excitation chamber 210 of FIGS. 19 to21, and like parts have been like numbered. The excitation chamber 220′differs from the excitation chamber 210 in that a flange 201′ ispresent, which can be called an intermediate flange because it connectsbetween the extremity or surfaces of the U-shaped tube 202′ and thecover 700 or similar as described below. The intermediate flange 201′may have a circular outer perimeter, that connects to the U-shaped tube202′. The flange 201′ has a recess or cavity 220.4, as best seen in FIG.27D2, and may have an outwardly facing circumferential groove 220.5,which has the purpose of providing a location for adhesive to beinserted, so as to bond a cover 700 as described below to the flange201′. The flange 201′ has two large apertures 201.11 which has acircumferential or circular inner rim 201.12 around it, and a co-axialcylindrical rim 220.3 which is of larger diameter to apertures 201.11,so as to receive the straight cut cylindrical rims 220.1 of the U-shapedtube 202′ terminus. On the other side of the flange 201′ to the rim220.3, is another co-axial cylindrical rim 220.2 which will receive astraight cut end of a cylindrical tube or bulb. The rim 201.12 providesa wall to separate the cylindrical ends 220.1 of the U-shaped tube 202′from engaging the straight cut ends of the cylindrical tubes or bulbslocated on the other side of flange 201′.

A space or gap 203′ will be formed as in the previously describedexcitation chambers, which will provide a gap into which a spool andcoil windings can be assembled. In this embodiment, the excitationchamber 220′ is made from a separate flange 201′ which is joined andsealed to the U tube 202′, in a gas tight manner. It will be noted fromthe Figs that the U-shaped tube 202′ has a flattened cross section onits tubular construction, while its ends are flared and terminate incylindrical rims, for engagement with the flange 201′.

Illustrated in FIGS. 27E to 27K is another excitation chamber 230′,which is similar to that of excitation chamber 220 of FIGS. 22 to 24,and excitation chamber 220′ of FIGS. 27A to 27D and like parts have beenliked numbered. In the preferred embodiment, the intermediate flange201′ of the excitation chamber 230′ is obround and of a geometry thatenables the excitation chamber 230′ to be physically smaller than thebulb size. If needed, the intermediate flange 201′ can exceed the bulbsize such that the excitation chamber cover and power controller can behoused compactly. Additionally, it will be noted from FIGS. 27E to 27Kthat the tubes of the U-shaped tubular portion 202′ have a major andminor axis, with the upper and lower leg segments of the U-shape havetheir major axes being collinear. The shape of the tubes of portion 202′is obround, and terminates in a flared end which in turn terminates in acircular or cylindrical rim 220.1 to engage the flanges 201′.

A difference between the chamber 230 of FIGS. 22 to 24 and chamber 203′of FIGS. 27E to 27K is that the excitation chamber 230 has a horizontaloffset portion 202.3 on the ends of each of the tubes 202, which leadsto the recess/cavity type mounting flanges 201. It will be understoodthat in some circumstances an offset, both in the same verticaldirection, or in opposite vertical directions, can be produced due tothe lamp requirements. The chamber 230′ can be manufactured in the sameway that chamber 220′ above is manufactured.

The production of an excitation chamber such as 220′ or 230′ with aseparate intermediate flange 201′ allows for an assembly of theexcitation chamber to the bulb, whereby the excitation chamber and bulbglass may differ. The ring 201.12 intermediates between the glass of theexcitation chamber and the glass of the bulb. The intermediate flange201′ allows for the accommodating of a thermal co-efficient differencebetween the bulb and the excitation chamber, by acting as a mediumbetween them, and also acts as a flux glass when they melt and or arefused together.

In respect of the manufacture of the excitation tubes 200, 210, 220,220′, 230 and 230′, an expected method of manufacture is described inthe flowchart of FIG. 28, to which some additional commentary isprovided as follows, wherein the number of the comment, namely 11 to 14,is located at, and directed to, particular steps in the flowchart ofFIG. 28.

Comment 11: Glass tubes are produced in a similar manner as described inthe first 6 steps of the flowchart of FIG. 15 and related Comments 1 to4 above.

Comment 12: The glass tubes are passed to a forming station where theyare heated to an elevated temperature wherein they are bent to form aU-shape after being partially pressurised with gas. The ends of the tubeare again heated and undergo a secondary forming process to produce themating or mounting flange 201 which later mates with the bifurcated bulbbody mounting flange 101.

Comment 13: The excitation chamber will index to the next stationwherein the amalgam and exhaust tubes will be attached.

Comment 14: This final stage comprises heating of the excitation suchthat the mating or mounting flange 201 can be trimmed to the finaldimensions and the mating face “sized”.

The plasma excitation chambers 200, 210, 220 and 230 can also be coatedexternally with a thermal barrier coating to isolate thermal radiationfrom the housed plasma. The excitation chambers 200, 210, 220 and 230,due to their relatively small size compared to the tubular lamp body,will also be somewhat isolated from radiation given off by the bulb bodywhen in operation and so will run cooler and more efficiently thancurrent lamps designs.

The plasma excitation chambers 200, 210, 220 and 230 can be produced ina single piece moulding and is initially envisaged to be constructed ofglass although other suitable materials may be used.

The plasma excitation chambers 200, 210, 220 and 230 will be mated withthe tubes or tubular bulbs and then welded, fused or otherwise joined,during the manufacture/assembly process, to the bifurcated tubes orstraight cut tubes as the case may be.

The construction of the above excitation chambers 200, 210, 220 and 230ensures that when in use (please also refer to the section belowentitled “Electromagnet geometry and its magnetic circuit”), theionisable gases will be excited at two locations in each excitationchamber or U-shaped pathway.

Ferrite Core Features and Construction

Illustrated in FIGS. 29 to 31 is a ferrite half core 300, which with alike half core 300 will form an electromagnet ferrite core, for anelectromagnet 400 (see FIGS. 50 to 97), for an electrodeless radiofrequency powered external closed core electromagnetic inductivelycoupled low pressure gas discharge light source or lamp.

The half ferrite core 300 has a body 301 being a circumferentialsection, which terminates at ends 303, with straight sides 301.1. At thecentre of the body 301 the core 300 has a straight projection or portion302, such that when two half cores are joined face to face, that is inmirror image of each other, so that their opposed ends 303 meet, therespective portions 302 will form a diametrical portion, that is, alonga diameter of a circle formed by the contacting bodies 301. The halfferrite core 300 has a generally rounded “E” geometry, similar to theEuro symbol.

Whilst the above describes a preferred design for an assembled ferritecore, it will be recognised that there are numerous variants to achievea similar magnetic circuit for the electromagnet and thus a lampconstruction. For example, a half toroid with a long middle portion 302,joining up with a half toroid, as in

.

The portion 302 is generally twice the cross sectional area of 301 andmay be any desirable shape with radiused, or rounded, edges 302.1. Asillustrated the portion 302 is generally rectangular or square shape.

The core 300 when joined to a like core to produce a circle with adiametrical line through it, can be described as a shape which includesa generally toroidal outer body with a centrally located diametricalportion formed from two opposed portions 302. This will form D-shapedapertures on each side of, or around, the centrally located diametricalportion formed from two opposed portions 302. When a coil is applied, asdiscussed in more detail below, this will produce a toroidal dipolemagnetic field.

The ferrite core 300 is produced as a half, as this allows easy assemblywith an excitation chamber such as 200, 210, 220 or 230 as discussedabove, when assembling a lamp such as lamp 1000, as will be discussedbelow. The half ferrite cores 300 are formed so as to be separatedthrough and re-joined through, a plane lateral to the direction ofextension of the centrally located diametrical portion formed from twoopposed portions 302.

Illustrated in FIGS. 32 to 34 is a half ferrite core 310, which issimilar to the ferrite core 300 described above. Like parts have beenlike numbered. The half ferrite core 310, has straight sections whichtangentially extend from the ends of the circumferential body portion301. This produces an “obround” ferrite core when respective ends 303 onadjacent half cores 310 are positioned together. This produces anobround shaped core and electromagnet 400, and is particularly usefulwhen assembled in a lamp with tubular bulb 140, as described in FIGS. 13and 14 above. The apertures formed through the assembled two cores 310will be approximately D-shaped just somewhat elongated.

Illustrate in FIGS. 41 to 43 is a ferrite core 310′ half which issimilar to the ferrite core half 310 of FIGS. 32 to 34, and like partshave been like numbered. They differ in that the core half 310′ whilestill having the general “E” shape, will form two vertically extendedapertures one being a side on D-shaped form:

; and the other an upside down side on D-

shaped form.

Electromagnet Geometry and its Magnetic Circuit

When assembled with a coil, two half ferrite cores 300, or 310, form anelectromagnet 400 as is illustrated in FIGS. 50 to 102, for use with alamp, such as the lamp 1000.

Preferably the coils of wire, which form the electromagnet 400, areformed and positioned at opposed locations on the centrally locateddiametrical portion made from two opposed central portions 302.

The electromagnet 400 formed from such a rounded double E geometryproduces a toroidal dipole electromagnet design that enables plasmaexcitation advantages previously not possible with current toroidalelectromagnet design. These include:

-   -   improved lamp system efficiency as one field winding effectively        energises two magnetic circuits;    -   improved magnetic coupling efficiency between the excitation        field and the plasma current generated; this enables a cooler        ferrite electromagnet therefore a smaller more efficient        electromagnet due to less heating from the plasma current of the        lamp;    -   improved ferrite core design, provides greater surface area to        interface with the gas discharge that enables smaller discharge        tubes to be used, hence physically smaller tubular lamps;    -   improved ferrite core design enables a smaller electromagnet        core of less weight and cost;    -   reduced electromagnetic interference due to the magnetically        enclosed field winding;    -   the reduced size ferrite core improves light utilisation of the        lamp;

The improvements to plasma excitation electromagnet 400, from thecompounded improvements in the spool 500, 510, and coil 600, 610, theferrite core 300, 310 etc., is that it enables an improved magneticcircuit design whereby the electromagnets 400 and excitation chambers200, 210, 220, 230, can be provided within the footprint or envelope(when viewing down the axial length of the tubular bulb or straight cuttubes) or the within the cross sectional area through a solid ofrevolution created by revolving the tubular bulb or two straight cuttubes, around a central longitudinal axis of the assembly.

Core Spool—Collapsible Field Winding Mounting Former

In order to assist with the assembly of the electromagnet 400 with andthrough the excitation chambers 200, 210, 220 and 230, a field windingmounting former or spool 500 has been developed, and is now described inmore detail with reference to FIGS. 35 to 49.

Illustrated in FIGS. 35 to 37 is a spool 500 for an electromagneticfield coil for an electromagnet. The spool 500 has a body 501 comprisinga generally tubular elongated construction which extends in the axialdirections of a central aperture 505 and has at least one winding saddle502, in this case two winding saddles 502, on a respective end of thebody 501. The saddles 502 are formed on the outside of the body 501 soas to coil or wind a wire 601, 602 to form a coil 600 (as illustrated inFIGS. 44 to 46). The spool 500 includes at least one end 501.1 which isdeformable allowing the spool 500 and the coil 600 to be manipulated forthreading through the space or gap 203 on an excitation chamber 200,210, 220, 230 being a tubular component of a lamp/excitation chamber.

In the event of only one winding saddle 502 or a coil 601 or 602 at onlyone end of the core spool, then the core spool may or may not have theability to deform at least one end of 501.1.

The ends 501.1 are of a generally square ring shape and at the upper andlower edges of the ring shape end 501.1 are four vertically extendingcoil retaining flanges 503. The ends 501.1 are interconnected by pair ofspaced axially extending arms 504. On the outboard side of one of thearms 504 is located a wire holder formation 506, which will hold a wiresegment 603 of the coil 600, which extends between the coils 601 and602. The ends 501.1 and the saddles formed by the vertically extendingcoil retaining flanges 503, will allow a coil of the shape of coil 600to be formed.

In the event of a coil only being present at one end of the core spoolthen the wire holder formation 506 may or may not be included.

The body 501 has the aperture 505 through it, so that the middle portion302 of ferrite cores 300 and 310 can be situated therein in a finalassembly.

The body 501 is manufactured from relatively thin sections of polymericmaterial such as Mylar or polyester, and thus has relatively littleweight. The skeletal nature of the body 501 also contributes to thisrelatively low weight. Additionally, the relatively thin structure ofthe ends 501.1 is such that, together with the large apertures in thebody 501 between the ends 501.1, allows the ends 501.1 to collapse bycompressive forces by squeezing the upper and lower sides of the ends501.1. When a coil 602 or 601 is located therein, this too willcollapse, lowering the profile of the end 501.1 and the coil 601 or 602,so that they can be pushed through, or squeezed through, the space orgap 203 on the excitation chambers 200, 210, 220, 230. Once in position,so that coil 601 and 602 are on either side of the space or gap 203, theends 501.1 can return to their original shape by material memory, orformations provided which may assist this, or be returned to theiroriginal shape by means of insertion of the ferrite core portion 302.

The deforming of the ends 501.1 can occur prior to, or during, insertionof a core portion 302 for the electromagnet 400.

In an alternative embodiment of the spool 500, the spool can be of muchthe same skeletal form, but one or both ring ends 501.1 can be maderotatable or pivotal with respect to the arms 504, so as to be rotatableabout an axis lateral to the direction of elongation of the body 501.This will allow the coil 601 or 602 to be pivoted or rotated, thuschanging the profile of the coil with respect to passage through thespace or gap 203, allowing thereby to be pushed through the gap 203.

The deformation of the ends 501.1 can be by elastic deformation orplastic deformation. If elastic it may resume its shape of its ownaccord, or if plastic, then assistance to regain its shape is requiredby later assembly processes, such as by insertion of a core portion 302of the electromagnet 400.

Illustrated in FIGS. 38 to 40 is another spool 510, which is similar tothat of spool 500 and like parts have been like numbered. The spool 510is especially useful with the excitation chamber 200 and 210 of FIGS. 16to 21. The spool 510 differs only in overall dimensions by comparison tothe spool 500.

Illustrated in FIG. 37A is a rectangular hollow spool 520, which can beused to from a coil 610 for use with the ferrite core of FIGS. 41 to 43,and then used in the excitation chamber assembly of FIGS. 62A to 62C.The spool 520 may be more cost effective to make than the spools 500 and510, due to its relatively simple shape and construction. It will benoted that in this configuration the spool 520 does not provide specificsaddles on its form, unlike the spools 500 and 510, which adds to theircomplexity. In this instance the spool 520 has peripheral lips 520.1 ateach end and a hollow middle 520.2 which allows core portions 302 topass into the spool 520. If desired the spool 520 can also be madewithout the peripheral lips 520.1. The spool 520 provides the advantagethat the coil 610 can be wound on either end as is the case in FIG. 92or FIG. 114 and, or if it is desired, across the whole length of thespool 520, that is between the rims 520.1, as in the case of FIG. 92,FIG. 97 or FIG. 101B, depending upon the excitation chamberrequirements.

The coils 600 and 610 which can be formed on the spools 500, 510, and520, can be formed so as to make coil segment 601 and 602 so thatappropriately sized and insulated wire, as would be commonly known to askilled person, can be wound thereon with as many windings as needed,depending upon the characteristics, such as strength and field shape, ofthe magnetic field that needs to be generated to create an appropriatelevel of induction in the excitation chamber.

By providing the coils 601 and 602 at spaced locations along the centralportion of the ferrite cores 300, 310 and 310′, and not the whole wayalong that central portion, facilitates heat dissipation and optimisesuse of the available excitation chamber.

Excitation Chamber and Electromagnet Assembly or Subassembly

Illustrated in FIGS. 50 to 53 is a series of illustrations of anassembly of the excitation chamber 200, with core 300, spool 500 andcoil 600, forming electromagnet 400, for the lamp assemblies of FIGS. 69to 88. It will be noted in the subassembly of FIGS. 50 to 53, that theferrite cores 300 are adjacent to the mounting flange 201, encapsulatingthe excitation chamber, which allows an excitation chamber cover 700(see description below) to be readily placed over the electromagnet 400and excitation chamber 200, and allowing the rim of the cover 700 to bereadily sealed to the outer rim of the mounting interface 101 of tubularbulb 100.

Illustrated in FIGS. 54 to 56 is a series of illustrations of anassembly of the excitation chamber 210, with core 300, spool 510 andcoil 600, forming electromagnet 400, which forms an alternativesubassembly that can be used with lamp assemblies of FIGS. 89 to 97where lamps are using straight or U-Tube constructions.

Illustrated in FIGS. 57 to 59 is a series of illustrations of anassembly of the excitation chamber 220, with core 300, spool 500 andcoil 600, forming electromagnet 400, for the lamp assemblies of FIGS. 89to 97.

Illustrated in FIGS. 60 to 62 is a series of illustrations of anassembly of the excitation chamber 230, with core 310, spool 510 andcoil 610, forming electromagnet 400, for the circular or toroidal lampassembly of FIGS. 98 to 101.

It will be noted from FIG. 62 that the excitation chambers are eachdesignated 230, with the one on the left in FIG. 62 being installed inan inverted condition by comparison to the excitation chamber 230 on theright in FIG. 62. This locates the evacuation tube 207 on the leftchamber 230 at the bottom, and the amalgam housing 206 also on theoutside of the assembly.

Illustrated in FIGS. 62A to 62C is a series of illustrations of anassembly of the excitation chamber 230′, with core 310′, a generallyrectangular spool and coil, forming electromagnet 400′, which can beused with a circular or toroidal lamp assembly of FIGS. 101A to 101C, orwith others as described above.

It will be also noted from FIG. 62 that each excitation chamber 230 hasonly respectively, one coil 601 or 602 located on one side only. Whilethe description of previous embodiments generally positions a coil 601and 602 on either side of an excitation chamber, this is only done as apreference, and only a single coil need be provided to a single side ofany excitation chamber 200, 210, 220, 220′, 230 or 230′ describedherein, if desired.

FIGS. 50 to 62C show the finished positions of the components mentionedabove. It will be noted in all of FIGS. 50 to 62C, that a space or gapis present between the upper surface of the upper tube of the excitationchambers and the under surface of the upper parts of the ferrite halfcores 300, and between the lower surface of the lower tube of theexcitation chambers and the upper surface of the lower parts of theferrite half cores 300. In production these spaces or gaps will befilled with an expanding foam or silicone product, or equivalentproduct, so that no relative movement between the excitation chambersand the ferrite cores can occur.

Excitation Chamber Cover—Passive Heatsink & Faraday Cage

Illustrated in FIGS. 63 to 65 is lamp excitation chamber cover 700 for alamp such as lamp 1000, which is an electrodeless radio frequencypowered external closed core electromagnetic inductively coupled lowpressure gas discharge light source. The excitation chamber cover 700includes a wall segment 701 manufactured from a metal, this wall segment701 being coated on an interior surface 701.1 with graphene.

The wall segment 701 includes an array of apertures 702 there through.That is each hole or aperture in the array passes through the wallsegment 701. While a distinctive linear or line based array of holes isutilised in the illustrations of FIGS. 63 and 64, it will be understoodthat any appropriate pattern, or random placement of holes, or groupingsof holes, will perform a similar function. Even if randomly placed, theholes may be considered to be in a random array or series.

The wall segment 701 is continuous and circular, that is generallycylindrical. But any shape, according to manufacturers or market needscould be utilised such as partially circumferential; box shape; squareshape; rectangular shape.

The interior surface 701.1 of the excitation chamber cover 700 can becoated with graphene, to assist it to perform its functions, asdescribed below.

While the excitation chamber cover 700 is preferably made wholly ofmetal, it may be possible to have a plurality of segments such as ametallised polymeric excitation chamber cover formation, making acomposite excitation chamber cover. Alternatively the excitation chambercover may be constructed of any material including a polymer orcomposite or other material capable of conducting an electric charge.

The excitation chamber cover 700 has a tapered section 703 at its basewhich turns down to the base flange 704 which has a radial flange 705,leaving an opening in the base of the excitation chamber cover 700. Theexcitation chamber cover 700 receives in its base a polymeric disc 709(visible in FIG. 73), which includes a plug and lamp holder cap and orelectric terminals 709.1 (see also FIG. 73) for connecting an assembledlamp to a supply of electricity.

The excitation chamber cover 700 includes or functions as one or both ofa faraday cage and a passive heat sink. It provides cooling of a ferritecore of an electromagnet and thus additionally provides thermalstability to an amalgam housing 206 and thus provides a stabletemperature environment, by controlling air flow around the at least oneexcitation chamber. It additionally provides physical protection tocomponents and any integral lamp controller electronics included withinthe excitation chamber cover or the lamp holder cap; is a means ormounting point for a lamp holder cap; and provides a bonding point forthe bulb.

The heatsink and faraday cage formed by the excitation chamber cover 700together with a graphene coating on the glass tubular bulb, andoptionally the excitation chamber(s), enables a charged surface to begenerated that will attenuate generated radio frequencies emitted fromthe assembled lamp when in operation.

Illustrated in FIGS. 66 to 68 is a second lamp cap 710, which is similarto that of an excitation chamber cover 700 and like parts have been likenumbered. The excitation chamber covers 700 and 710 differ only ingeneral shape in that the excitation chamber cover 710 is of an obroundshape which is used to match the obround nature of the assembled ferritecores 310 of the electromagnet 400 of FIGS. 60 to 62, for use with thetubular bulb 140 of FIGS. 13 and 13A, and the lamp assembly of FIGS. 98to 101.

A another excitation chamber cover 710′ is Illustrated in FIGS. 101B and101C, which is similar to that of excitation chamber cover 710. Theexcitation chamber covers 710 and 710′ differ only in that theexcitation chamber cover 710′ is for use with the tubular bulb 140′ ofFIGS. 14 and 14A, or square tube 140″ of FIG. 101C and the lamp assembly1600′ and 1600″ of FIGS. 101A to 101C, and must be shaped on its sideaway from the bulb to receive an obround lamp holder and with recessedconnectors, at approx. 90 degrees to the plane of the bulb, asillustrated in FIG. 101C.

Lamp Assembly

Illustrated in FIGS. 69 to 101C are assembly illustrations for thedifferent configurations of lamps that are possible from the abovedescribed components.

FIGS. 69 to 73 illustrates a lamp assembly 1000, being a double endedlamp, made from the tubular bulb 100 with tubes of circular crosssection, and at both ends, an excitation chamber 200 or 210, two ferritecores 300, spool 500, coil 600 to form electromagnet 400, covered atboth ends by a cover 700, which respectively seal to the outer rims ofthe bulb mounting flanges 101.

FIGS. 74 to 79 illustrates a lamp assembly 1100, being a single endedlamp, having the tubular bulb 110 with tubes of circular cross section,and at one end an excitation chamber 200 or 210, two ferrite cores 300,spool 500, coil 600 to form electromagnet 400, covered at its end by aexcitation chamber cover 700, which is sealed to the outer rim of thebulb mounting flange 101.

FIGS. 80 to 84 illustrates a lamp assembly 1200, being a single endedlamp, having the tubular bulb 130 with opposed piriform cross section(which may also be described as being of a sextic form), and at one endan excitation chamber 200 or 210, two ferrite cores 300, spool 400, coil600 to form electromagnet 400, covered at its end by a excitationchamber cover 700, which is sealed to the outer rim of the bulb mountingflange 101.

FIGS. 85 to 88 illustrates a lamp assembly 1300, being a double endedlamp, made from a bifurcated bulb 120, with opposed piriform crosssection and at both ends, an excitation chamber 200 or 210, two ferritecores 300, spool 500, coil 600 to form electromagnet 400, covered atboth ends by a excitation chamber cover 700, which respectively seal tothe outer rims of the bulb mounting flanges 101.

FIGS. 89 to 93 illustrate a lamp assembly 1400, being a double endedlamp, made from two straight cut cylindrical glass tubes to form thetubular bulbs, and at both ends, an excitation chamber 220 into whichthe tubes fit directly, two ferrite cores 300, spool 500, coil 600 toform electromagnet 400, covered at both ends by excitation chamber cover700, each of which respectively seals to the outer rim of the ferritecore 300. This lamp 1400 incorporates two plasma excitation chambers 220as required for a double ended lamp so that the tubes 102 interface withthe excitation chamber cavities to create a gas tight seal. The lamp1400, as best illustrated in FIG. 89 includes a fascia cap 702.1 throughwhich is passed the glass tubes 102, before they are fused to theexcitation chamber 220. The fascia cap 702.1 can be secured to or sealedwith the inside rim of the excitation chamber cover 700. A similarfascia cap 702.1 will be present on the other side, but has been removedfor illustration purposes. The fascia cap 702.1 can be provided foraesthetic reasons, and as such can be optional. In the case of visiblelight lamps such fascia caps 702.1 may be required to act as a shield toprevent emission of electromagnetic radiation from the excitationchamber.

FIGS. 94 to 97 illustrates a lamp assembly 1500, being a single endedlamp made from two straight cut cylindrical glass tubes to form thetubular bulbs, and at one end, an excitation chamber 220 into which thetubes fit directly, two ferrite cores 300, spool 500, coil 600 to formelectromagnet 400, covered at its end by excitation chamber cover 700,which seals to the outer rim of the adjacent bulb mounting flange 101.This lamp 1500 incorporates one plasma excitation chamber 220, as ashaped bent tube with flared ends which physically integrates into apair of circular tubular bulb ends of a U-tube for a single ended lamp,so that the tubes interface with the excitation chamber cavities tocreate a gas tight seal whilst maintaining the same plane of theparallel tube bulb.

FIGS. 98 to 101 illustrates a lamp assembly 1600 being a ring shapedtubular lamp made from the bulb 140, to which has been assembled anexcitation chamber 230, in the manner illustrated in FIGS. 60 to 62.Also assembled is the spool 510 with coil 610 to form an electromagnet400, and this is all covered by a excitation chamber cover 710, whichseals to the outer surface of the ferrite core assembly.

In the lamp 1600, tube 102 of the bulb 140 is connected to theexcitation chamber 230, so that only a single ionization gas circuit isproduced. If desired, the excitation chambers 230 can be oriented andconnected to the mounting flanges 101 on tubes 102, so that the uppertube 102 is in a separate circuit to that of the lower tube 102.

Illustrated in FIGS. 101A to 101B is a lamp 1600′ which is similar tolamp 1600 of lamp 98 to 100, except that the bulb is comprised of asingle tube. Other differences include that the wires from the coils ofthe electromagnet or two and from the power controllers, are connectedto terminals 709.1 behind the cover 710′, which are located in a cavity709.2 as best seen in FIG. 101C, which are at right angles to the planeof the bulb.

Illustrated in FIG. 101C is a lamp 1600″, which is similar to that ofFIGS. 101A and 101B, except that the circular or part toroidal bulb 140′is replaced by a square tubular bulb 140″.

FIGS. 104 to 108 illustrate a lamp assembly 1700, being a double endedlamp, made from two straight cut cylindrical glass tubes 102 to form thetubular bulbs, and at both ends, an excitation chamber 210 into whichthe tubes fit directly, two ferrite cores 300, spool 500, coil 600 toform electromagnet 400, covered at both ends by excitation chamber cover700, each of which respectively seals to the outer rim 201.1 of theexcitation chamber 210. The lamp 1700 is similar in construction to thelamp 1500 of FIGS. 89 to 93, except that the excitation chamber 210 isutilised. This lamp 1700 incorporates two plasma excitation chambers 210as required for a double ended lamp so that the tubes 102 interface withthe excitation chambers' cavities to create a gas tight seal.

FIGS. 109 to 113 illustrate a lamp assembly 1800, being a single endedlamp, made from two straight cut cylindrical glass tubes 102 to form thetubular bulbs, and at one end, an excitation chamber 210 into which thetubes fit directly, two ferrite cores 300, spool 500, coil 600 to formelectromagnet 400, covered at its end by cover 700, which seals to theouter rim 201.1 of the excitation chamber 210. The lamp 1800 is similarin construction to the lamp 1500 of FIGS. 94 to 97, except that theexcitation chamber 210 is utilised. This lamp 1800 incorporates a singleplasma excitation chamber 210 as required for a single ended lamp sothat the tubes 102 interface with the excitation chamber cavities tocreate a gas tight seal.

FIG. 114 illustrates a lamp assembly 1400′, which is similar to that oflamp assembly 1400 of FIGS. 89 to 92 as described above. The assembly1400′ has its right end in an exploded view, which shows the componentsof the excitation chamber 220′ and intermediate flange 201′ as describedabove, ferrite core 300, an elongated spool 520′ like spool 520described above, on which coils 600 or 610 are wound on the opposedends, and a cover 700 and lamp holder 709. It will be noted from FIG.114 that straight cut cylindrical tubes 102 are used for assembly to theintermediate flanges 201′.

While specific lamp types 1000, 1100, 1200, 1300, 1400, 1400′, 1500,1600, 1600′, 1600″, 1700 and 1800 are illustrated and described above,other combinations of components can be made. For example, electromagnet400/dual excitation chamber 230 assembly of FIGS. 60 to 62 can beutilised with two U-shaped tubes with straight cut ends. If eachU-shaped tube has its ends fitted to one excitation chamber 230, then aseparate circuit will be formed in each U-shaped tube. Whereas if oneend of one U-shaped tube is connected to a first excitation chamber, andthe other end is on the second excitation chamber, and likewise for thesecond U-shaped tube, then a single circuit on a single ended lamp willbe produced.

Additionally, the electromagnet 400 and dual excitation chamber 230assembly of FIGS. 60 to 62 can be utilised with 4 separate straighttubes, each with one closed end and one open end. Further, if twoassemblies of the electromagnet 400 and dual excitation chamber 230assembly of FIGS. 60 to 62 were positioned opposite and facing eachother, then respective opposed pairs of mounting flanges 201 can bejoined to straight cut cylindrical shaped bulbs, making a four bulbdouble ended lamp, having two circuits. If one assembly of FIGS. 60 to62 is instead rotated through 90 degrees, before connecting the tubesthis will produce a double ended, four tube, single circuit lampassembly.

The assembly procedure is schematically illustrated in FIG. 102, whichneeds to be read in conjunction with the following comments, the numberof the comment, namely 15 to 23, being located in the flowchart of FIG.15.

Comment 15: The completed bulb body e.g. 100, and excitation chamberse.g. 200, will be introduced to an assembly station where they will bepositioned, held and fused, welded or otherwise joined together withheat to create the lamp body.

Comment 16: A graphene coating will be applied to the outer surface ofthe lamp body assembly, that is the tubular bulb e.g. 100 and excitationchamber e.g. 200.

Comment 17: A vacuum will be applied to the lamp body prior to theintroduction of an operating gas, insertion of mercury or an amalgam,via the exhaust tube 207 and amalgam tube 206. The exhaust and amalgamtubes will be sealed to create an airtight lamp body.

Comment 18: A heat barrier coating will be applied to the excitationchamber ends. A silicon or similar compound will be applied to theexcitation chamber in the areas which interface with the ferrite.

Comment 19: The core spool and winding will have been assembled andintroduced as a complete assembly to the production line. The core spoolwith its integral winding will be partially collapsed or deformed insuch a manner that it can be fed into the spacing or gap 203 between thetubes 202 of the U-Shaped sections of the excitation chambers e.g. 200whereupon it will expand back, or be expanded back, to its designatedshape.

Comment 20: The half ferrite cores e.g. 300 will be fed into either sideof the aperture 505 of the spool e.g. 500 being the core spool/windingassembly and around the outer side of the excitation chamber e.g. 200.Care will be taken to not wipe away the silicon coating or similarcoating which had been previously applied to the outer faces of theexcitation chamber e.g. 200 where it passes through the half ferritecores e.g. 300. The half ferrite cores 300 will be fused together, attheir abutting ends 303 by heat, or laser welding etc. and or aconductive filler material if preferred by the manufacturer.

Comment 21: An excitation chamber cover 700 will be introduced to theassembly line and a lining of graphene applied to the internal face.

If the particular model of lamp includes an integral controller(Electronic Control Gear or ECG), then the ECG will be installed andmechanically affixed and electrically connected to and within theexcitation chamber cover 700.

The end wires of the coils 601 and 602, commonly called fly wires willbe soldered to the lamp holder cap electrical terminals, or in the caseof an integral ECG, to the ECG which in turn will be connected to thelamp holder cap electrical terminals.

Comment 22: An adhesive or amalgam solder will be applied to the outersurface of the excitation chamber e.g. 201.1 in the area which willinterface with the excitation chamber cover 700.

The excitation chamber cover 700 is fitted over the ferrite core outersurface and secured by means of adhesive or amalgam to the outer face ofthe excitation chamber lamp body.

Comment 23: The complete bifurcated lamp is now tested for technical andfunctional performance.

Variations to the above method will be needed according to which lampassembly 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1600′, 1600″, 1700 or1800 is being manufactured.

It will be noted that the double ended lamps 1000, 1300 and 1400, areeach illustrated as being directly connected to electricity at each end.If desired, for these double ended lamps, as can be seen in FIG. 103(see sheet 3/32 of the drawings), there can be provided an aperture104.1 in and through the transition surface 101.2 on opposite ends ofthe lamp, which will permit the passage of a power take off conductorfrom the electrics of one end of the lamp to the other, ensuring thatthe lamp will only need connection to electricity at one end. If needed,a second pair of holes on the other side can be provided for a returnconductor.

It will be noted from the above description, that dimensions are notprovided, such as wall thickness, length or height or width of tubularbulb; diameter of tubes etc. This is because a person skilled in the artof bulb making, will according to what materials are used, what lampcharacteristics are to be obtained, what machinery to make and assemble,will select such dimensions according to needs and conditions, and sometrial and error may be required before selecting the dimension to beactually manufactured.

While in the above embodiments and their description, and in some of theclaims below, there is utilised the expression “gas communication”, itwill be understood that this will include liquid communication if aliquid is included in substances held within the bulb. Further, onceexcited, the expression “gas communication” will include plasmacommunication to facilitate creation and or sustain plasma through thetubes and the excitation chambers.

ADVANTAGES AND BENEFITS OF THE LAMP ASSEMBLIES

The above described lamp assemblies have some of the following benefits.

By locating the amalgam housing 206 behind the mounting flanges 101 and201, and by utilising a relatively small thermally insulated excitationchamber e.g. 200 in such a manner that it is thermally isolated from theluminous radiation from the tubular bulb e.g. 100 of the lamp e.g. 1000the amalgam housing will be thermally stabilised. The amalgam thereforeoperates more efficiently than currently occurs with existing inductionlamp designs in the market place.

The deformable or collapsible spool e.g. 500 which is a field windingmounting former, enables automated precision field winding and collapsesin such a manner to facilitate easy entry to the excitation chamber e.g.200 entry aperture or gap 203, and thus a relatively fast, easy assemblyduring the manufacturing process.

The design of the lamps, enable miniaturisation of an electrodeless lampwith both integral and external low to medium RF powered electromagneticfield to achieve excitation of a low pressure gas to generate a plasma.

The design of the components described above, assists in reducing thecost of lamp manufacture without compromising intrinsic induction lampperformance.

The embodiments described above enable manufacture of both linear andbulbular low pressure induction lamps on modified existing conventionallamp making machines, and allows automated simplification of lowpressure induction lamp manufacture.

The embodiments of the invention will also allow self-ballasted lowpressure induction lamps to be retrofitted in existing lamp socketswhich previously used a self-ballasted lamp of either bulbular GLSincandescent, compact fluorescent, linear or bulbular LED or some othertype of lamp. When replacing a lamp which previously used an externalballast, the previous ballast will be disconnected and replaced with asuitable low pressure induction lamp controller (ballast), or will bedisconnected and replaced by a self-ballasted low pressure inductionlamp.

Currently all low pressure induction lamps are physically large fortheir respective light or UV radiation output which makes these lampsunappealing for commercial and residential use. This relegates theirapplication to low volume specialised use, and they are expensive tomanufacture. It is expected that this will be reversed with theembodiments described above.

The embodiments described above enable miniaturisation of the keycomponents of a low pressure induction lamp construction and thusachieves a smaller, lower cost light source without compromising theintrinsic induction lamp performance. This makes the lamps of the aboveembodiments more appealing to users and therefore potentially broadensapplications, enabling larger market opportunities.

The lamps typical of 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1600′,1600″, 1700, and 1800 have a diverse performance range of the order of 2W extending to 2000 W. This is supported by the electromagnet assemblygeometry and the resultant magnetic circuit allowing greater surfacearea of magnetic coupling within the excitation chamber. The geometryaffords a compact excitation chamber for narrow profile tubular andbulbular lamps of narrow cross section. The geometry also effectivelycreates two toroidal magnetic couplings while utilising only one fieldwinding, thereby reducing power losses.

The lamps 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1600′, 1600″, 1700and 1800 are expected to be simpler, cheaper and faster to manufacturerthan existing magnetic induction lamps using conventional lamp glassmaking machinery.

While the lamps 1600, 1600′ and 1600″ all show tubular bulbs which areround or square in shape, and other lamps have bulbs which are linear,it will be understood that the embodiments described above can beapplied to bulbs of any shape, including rhomboid, triangular,hexagonal, ellipsoidal and many other shapes.

Where ever it is used, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

It will be understood that the invention disclosed and defined hereinextends to all alternative combinations of two or more of the individualfeatures mentioned or evident from the text. All of these differentcombinations constitute various alternative aspects of the invention.

While particular embodiments of this invention have been described, itwill be evident to those skilled in the art that the present inventionmay be embodied in other specific forms without departing from theessential characteristics thereof. The present embodiments and examplesare therefore to be considered in all respects as illustrative and notrestrictive, and all modifications which would be obvious to thoseskilled in the art are therefore intended to be embraced therein.

The invention claimed is:
 1. An electrodeless lamp or electrodelesselectromagnetic radiation source having: an excitation chamber assemblywhich includes an excitation chamber formed from a generally U-shapedtube; a tubular lamp bulb having ends which are joined to ends of saidgenerally U-shaped tube; a cover which covers said excitation chamberassembly; a flange which connects between said cover and said generallyU-shaped tube or said tubular lamp bulb; an amalgam housing which isconnected to said generally U-shaped tube and which is part of saidexcitation chamber assembly; and an electromagnetic circuit which whenactivated creates an inductively coupled plasma in said excitationchamber and said tubular lamp bulb, said electromagnetic circuit beingpart of said excitation chamber assembly; and said cover and said flangeproviding thermal isolation of said electromagnetic circuit and theamalgam housing from the tubular lamp bulb.
 2. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 1,wherein said excitation chamber assembly also includes one or acombination of two or more of the following features: an electromagneticcore which is part of said electromagnetic circuit; a field coil whichis part of said electromagnetic circuit; a thermal barrier coating; andgraphene coating on the outside of said excitation chamber.
 3. Theelectrodeless lamp or electrodeless electromagnetic radiation source asclaimed in claim 1, wherein said electromagnetic circuit is a toroidaldipole magnetic circuit with a centrally located field coil or coils. 4.The electrodeless lamp or electrodeless electromagnetic radiation sourceas claimed in claim 1, wherein said electromagnetic circuit utilises acore which is formed from a rounded double E geometry core magneticcircuit.
 5. The electrodeless lamp or electrodeless electromagneticradiation source as claimed in claim 1, wherein said flange is at one ofthe following locations: on said ends of said generally U-shaped tube;on ends of said tubular lamp bulb; between said tubular lamp bulb andsaid ends of said generally U-shaped tube.
 6. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 1,wherein the lamp or radiation source has one of the following:controllers or power controllers; controllers or power controllers beingremote with the lamp or source; controllers or power controllers beingintegral with the lamp or radiation source.
 7. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 1,wherein the lamp or radiation source has one of, or a combination of twoor more of the following: said cover being coated with graphene; saidcover being made of a metallic material; said cover being made of anon-metallic material that is coated with graphene; said cover beingcoated with graphene to form a faraday cage; said cover being of asingle piece construction; said cover being of a multiple piececonstruction.
 8. The electrodeless lamp or electrodeless electromagneticradiation source as claimed in claim 1, wherein said tubular lamp bulbis formed from two tubes which are not connected along their length, butare in gas communication with each other at an end opposite to thelocation of said excitation chamber assembly.
 9. The electrodeless lampor electrodeless electromagnetic radiation source as claimed in claim 1,wherein said tubular lamp bulb is formed from two tubes which areconnected intermittently or continuously along their length, and are ingas communication with each other at an end opposite to the location ofsaid excitation chamber assembly.
 10. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 8,wherein said two tubes at an end opposite to the location of saidexcitation chamber assembly are joined by a joining member which is oneof the following: separate from said two tubes to form at least a gascommunicating passage between said tubes; integrally formed with saidtwo tubes to form at least a gas communicating passage between saidtubes.
 11. The electrodeless lamp or electrodeless electromagneticradiation source as claimed in claim 9, wherein said two tubes at an endopposite to the location of said excitation chamber assembly are joinedby a joining member which is one of the following: separate from saidtwo tubes to form at least a gas communicating passage between saidtubes; integrally formed with said two tubes to form at least a gascommunicating passage between said tubes.
 12. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 1,wherein said tubular lamp bulb is of any cross sectional shape includingone of the following cross sectional shapes: round; square; elliptical;ellipsoid; tear drop shape; triangular; triangular where apexes areoppositely facing each other; tear drop shape where the apexes areoppositely facing each other.
 13. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 1,wherein there is included at least one exhaust tube.
 14. Theelectrodeless lamp or electrodeless electromagnetic radiation source asclaimed in claim 1, wherein there is included at least one exhaust tubewhich is connected to said generally U-shaped tube and which is part ofsaid excitation chamber assembly.
 15. The electrodeless lamp orelectrodeless electromagnetic radiation source as claimed in claim 1,wherein said electromagnetic radiation is in one, or more than one, ofthe following spectrums: ultraviolet; visible light; infra-red.